INS-MAR-01 (Rev9)
BONDSTRAND FIBERGLASS PIPING
INSTALLATION MANUAL
PROJECT REFERENCE NO:
DOCUMENT NO.:
INS-MAR-01
DATE:
11st AUG- 2016
Rev. No:
Rev. 9
Page 1 of 40
INS-MAR-01 (Rev9)
Content List
1
Introduction ...................................................................................................................5
2
Reference ......................................................................................................................5
3.
Pipe Arrangement ...........................................................................................................5
4.
5
3.1
Layout................................................................................................................5
3.2
Spool breaking ...................................................................................................5
3.3
Conductivity and Grounding (Applicable on conductive system only) ................6
Supports ........................................................................................................................7
4.1
General guidance ...............................................................................................7
4.2
Support span ......................................................................................................7
4.2.1
Maximum Support Span .............................................................................7
4.2.2
Support span at Double O-Ring Expansion Joint ........................................8
4.2.3
Support Span at Mechanical Expansion Joint ..............................................9
4.3
Axial load on anchor support............................................................................ 10
4.4
Support type and detail ..................................................................................... 11
4.4.1
Guide support ........................................................................................... 11
4.4.2
Fixed support (Light anchor) .................................................................... 12
4.4.3
Anchor support ......................................................................................... 12
4.4.4
Flange Frame............................................................................................ 13
Receiving, Handling, Storage....................................................................................... 14
5.1
Receiving ......................................................................................................... 14
5.2
Handling .......................................................................................................... 14
5.3
Transportation .................................................................................................. 14
5.4
Lifting .............................................................................................................. 15
5.5
Storage ............................................................................................................. 15
5.5.1
Pipe .......................................................................................................... 15
5.5.2
Fittings ..................................................................................................... 15
5.5.3
Fabricated Spools ..................................................................................... 15
5.5.4
Adhesives ................................................................................................. 16
5.5.5
Accessories .............................................................................................. 16
Page 2 of 40
INS-MAR-01 (Rev9)
5.5.6
6
Tools ........................................................................................................ 16
Installation of Fiberglass Pipe ...................................................................................... 17
6.1
Adhesive bonding joint (Only applicable for up to 40” ) ................................... 17
6.1.1
Special Tools for adhesive bonding joint .................................................. 17
6.1.2
Bonding Procedure ................................................................................... 17
6.2
Flange assembly ............................................................................................... 20
6.2.1
Gaskets ..................................................................................................... 20
6.2.2
Bolts ......................................................................................................... 20
6.2.3
Assembly ................................................................................................. 20
6.2.4
Flange mounting misalignment tolerances ................................................ 20
6.2.5
Recommended Bolt Torque ...................................................................... 21
6.2.6
Tightening Sequence as per ASTM D4024 ............................................... 22
6.3
Double O-Ring Joint Assembly (Only applicable for up to 40”) ....................... 23
6.3.1
Preparation and pre-set ............................................................................. 23
6.3.2
Insertion depth and Accessories ................................................................ 23
6.3.3
Inspection prior to assembly ..................................................................... 24
6.3.4
Assembly integral DOF – DOM Joint ....................................................... 25
6.3.5
Assembly Double o-ring expansion coupling ............................................ 26
6.3.6 All o-rings and nylon keys for the GRE expansion couplings are to be kept in a
cool dry place, away from heat or direct sunlight to prevent deterioration of the
materials. ..................................................................................................................... 27
6.4
7
Mechanical Coupling Joint Assembly ( Only applicable for up to 40” ) ............ 27
6.4.1
Preparation and pre-set ............................................................................. 27
6.4.2
Inspection ................................................................................................. 28
6.4.3
Assembly ................................................................................................. 29
6.5
Connection to Other Materials.......................................................................... 29
6.6
Connections to equipment, tanks, pressure vessels ........................................... 30
6.7
Maximum allowable misalignment tolerances .................................................. 30
6.8
Installation in Hull/Topside Block .................................................................... 31
Test of Fiberglass Pipe System .................................................................................... 33
Page 3 of 40
INS-MAR-01 (Rev9)
7.1
7.1.1
Test general recommendations.................................................................. 33
7.1.2
Test medium and test pressure .................................................................. 33
7.1.3
Inspection, acceptance criteria, and approval ............................................ 33
7.1.4
Effect of temperature ................................................................................ 34
7.1.5
Reinstatement ........................................................................................... 34
7.1.6
Safety ....................................................................................................... 34
7.2
8
9
Hydro-test ........................................................................................................ 33
Conductivity test (For Conductive System Only).............................................. 34
7.2.1
Test methods ............................................................................................ 34
7.2.2
Acceptance criteria ................................................................................... 35
Field Modification and Repair ..................................................................................... 36
8.1
Modification and repair procedure.................................................................... 36
8.2
Modification and repair general concerns ......................................................... 36
8.3
Common modification and repair methods ....................................................... 36
8.3.1
Partial replacement ................................................................................... 36
8.3.2
Over-wrap ................................................................................................ 37
8.3.3
Surface repair ........................................................................................... 38
8.4
Temporary repair ............................................................................................. 38
8.5
Other methods and solutions ............................................................................ 38
Safety Recommendation .............................................................................................. 39
9.1
Dust Hazards .................................................................................................... 39
9.2
Chemical Hazards ............................................................................................ 39
9.3
Spill and Disposal ............................................................................................ 40
Important Notice ................................................................................................................. 40
Copyright ............................................................................................................................ 40
Revision Notes .................................................................................................................... 40
Page 4 of 40
INS-MAR-01 (Rev9)
1
Introduction
This installation manual is to provide installers a comprehensive overview for installation
of NOV fiberglass pipe systems, on marine projects, such as, ships, FPSOs, Drilling
Units, Etc.
Characteristics for marine installations are, piping is arranged in confined space; and the
installation work is significantly affected by hull/topside structure design, fabrication and
erection. Therefore it is necessary to take special precaution and follow the included
recommendations for installation.
This manual contains material on receiving and handling, piping layout and support
principles. The manual also covers various types of joint assembly, followed by hydro
test and conductivity test procedures.
In case any site modification is required, or any damage on fiberglass piping system
occurs, modification and repair recommendation are provided.
General health and safety recommendations are given in the last chapter of the manual.
2
3.
Reference
AME/INS-004
Hydro-testing procedure for Bondstrand GRE/GRV pipe
AME/INS-003
Procedure for conductivity and grounding of GRE pipe
MOD-01, 02, 03
Modification and Repair Recommendation
Pipe Arrangement
3.1 Layout
Fiberglass piping shall be routed in such a way that:
-
It is in accordance with specification and piping diagram;
-
The number of direction change are minimized to reduce the surge effect on the
fiberglass piping system;
-
It allows sufficient expansion joints in appropriate locations for ship sagging and
hogging effect, and also be able to accommodate minimal fabrication, erection
and installation deviation of hull/topside structure and piping work;
-
It provides for ease of installation;
-
Ease of supporting. Supports can be easily located and fabricated;
-
Certain flexibility is provided in the system to enable joint assembled to the
correct dimensions without the need to pull/push a spool into position.
3.2 Spool breaking
The use of prefabricated spools shall be maximized to minimize the amount of site
adhesive jointing work. Fiberglass piping shall be broken for spooling in such a way:
Page 5 of 40
INS-MAR-01 (Rev9)
-
To avoid/minimize site adhesive bonding joint;
-
To not exceed handling capacity of installation, and transportation equipment or
facilities;
-
To make it feasible to bring the spool into position after hull/topside-block
erection;
-
That no spool will protrude through the hull/topside block after installation in
block;
-
That the breaking point shall be located at accessible location.
3.3 Conductivity and Grounding (Applicable on conductive system only)
NOV FGS conductive fiberglass pipe, fittings and flanges incorporate high strength
conductive filaments to prevent accumulation of potentially dangerous levels of static
electrical charges by the flow of liquids or other environmental causes.
Accumulated charges are harmlessly drained from the fiberglass pipe system into the
metallic hull/topside structure by means of:
-
Flange connection to metallic flange of metallic piping, equipment, tanks,
bulkhead penetration and so on;
-
Flange frame support at fiberglass flange. The flange frame is bolted at the back
of fiberglass flange, and the base of flange frame will be connected to steel
structure.
-
Grounding saddle with embedded stainless steel cable, one end is bonded onto
pipe surface, and the other end is bolted to steel structure.
Sufficient electrical drainage points shall be installed to enable a completely conductive
system.
Grounding saddles shall be mounted on the pipe section that is isolated from other
means of electrical drainage. Mechanical coupling joints and double o-ring joints are
considered as isolating points or conductivity breaking points.
In general, the grounding saddle shall be positioned near a support, so that the
extension cable of the grounding saddle can be fixed on the support structure,
avoiding disruption to the primary hull/top side structure.
Page 6 of 40
INS-MAR-01 (Rev9)
4.
Supports
4.1 General guidance
Piping supports shall be arranged in such a way that:
-
Supports shall be arranged to avoid sag and/or excessive vibration;
-
Valves, and other heavy in line items shall be independently supported;
-
Hose connections, utility or loading stations shall be supported to avoid
excessive bending stress;
-
Fiberglass pipe shall not be used to support other piping;
-
Enough space is provided between support and fittings to ensure that pipe
movement is not obstructed either axially or laterally;
-
Supports shall be located at convenient and accessible location;
-
Supports shall be preferably located on plain-pipe sections rather than at
fittings or joints;
-
A fixed support must be located along the length of the straight pipe/spool if
both ends are connected with unrestrained mechanical joints;
-
An anchor support shall be installed between an unrestrained mechanical joint
and an elbow, a tee or a reducer.
4.2 Support span
4.2.1 Maximum Support Span
Recommended maximum spans for NOV FGS pipe at operating temperatures
66C and below are listed below. These spans are intended for normal
horizontal piping arrangements. The tabular values are for partial span that
represent a compromise between continuous and simple spans.
Size (mm)
1” (DN25)
1-½” (DN40)
2” (DN50)
3” (DN80)
4” (DN100)
5” (DN125)
6” (DN150)
8” (DN200)
10” (DN250)
Product Series: 2000M & 7000M
Span
Span
Size (mm)
Size (mm)
(m)
(m)
3.0
12” (DN300)
6.0
30” (DN750)
3.5
14” (DN350)
6.0
32” (DN800)
3.8
16” (DN400)
6.0
36” (DN900)
4.3
18” (DN450)
6.0
40” (DN1000)
4.9
20” (DN500)
6.0
48” (DN1200)
5.2
22” (DN550)
6.0
52”(DN1300)
5.5
24” (DN600)
6.0
60”(DN1500)
6.0
26” (DN650)
6.0
6.0
28” (DN700)
6.0
Span
(m)
6.0
6.0
6.0
6.0
6.0
6.0
6.0
Note: Consult NOV FGS for product series others than 2000M & 7000M.
Page 7 of 40
INS-MAR-01 (Rev9)
4.2.2 Support span at Double O-Ring Expansion Joint
Supports shall be arranged at both sides of Double O-Ring Expansion Joint.
The support shall be positioned in such a way that it will not cause obstruction
to dismantling/assembly of the joint, and it provides good support for the
weight effect of the joint assembly.
Neylon Key
Support Clamp
Double O-ring
Expansion Coupling
Product Series: 2000M & 7000M ( only applicable for up to 40” )
Size
A-min (m)
A&B-Max (m)
C-min (m)
2” (DN50)
0.23
1.0
0.30
3” (DN80)
0.23
1.0
0.30
4” (DN100)
0.23
1.0
0.30
5” (DN125)
0.25
1.0
0.36
6” (DN150)
0.25
1.5
0.36
1.5
8” (DN200)
0.30
0.44
10” (DN250)
0.33
1.5
0.46
1.5
12” (DN300)
0.38
0.53
14” (DN350)
0.40
1.5
0.55
1.5
16” (DN400)
0.43
0.58
18” (DN450)
0.45
2.0
0.54
20” (DN500)
0.49
2.0
0.56
22” (DN550)
0.53
2.0
0.62
24” (DN600)
0.55
2.0
0.62
26”(DN650)
0.60
2.0
0.70
28” (DN700)
0.63
2.0
0.72
30” (DN750)
0.63
2.0
0.73
32” (DN800)
0.68
2.0
0.82
36” (DN900)
0.68
2.0
0.95
40” (DN1000)
1.00
2.0
0.95
Page 8 of 40
INS-MAR-01 (Rev9)
Note:
A-min denotes the recommended minimum distance for Double O-ring
Male (DOM) end to avoid interference between clamp and fiberglass
component;
A&B-max denotes the recommended maximum distance of the support;
C-min denotes the minimum clearance for assembly/dismantling of
Double O-ring Expansion Coupling;
4.2.3 Support Span at Mechanical Expansion Joint
Supports shall be arranged at both sides of Mechanical Expansion Joint. The
support shall be positioned in such a way that it will not cause obstruction to
dismantling/assembly of the mechanical expansion coupling, and it provides
good support for the weight effect of the joint assembly.
Support Clamp
Mechanical End
Mechined End
B
A
Product Series: 2000M & 7000M ( only applicable for up to 40” )
Size (mm) A-min (m) B-Max (m) Size (mm) A-min (m) B-Max (m)
50
0.35
1.0
450
0.39
2.0
80
0.35
1.0
500
0.42
2.0
0.42
100
0.35
1.0
550
2.0
0.42
125
0.36
1.0
600
2.0
0.42
150
0.36
1.5
650
2.0
1.5
0.42
200
0.37
700
2.0
0.42
250
0.38
1.5
750
2.0
1.5
300
0.38
800
2.0
350
0.38
1.5
900
2.0
400
0.38
1.5
1000
2.0
Page 9 of 40
INS-MAR-01 (Rev9)
4.3 Axial load on anchor support
When a mechanical joint and/or double o-ring joint is in place together with a bend,
the strength of the steel structure of axial stop type support is the essential to the
reliability of the piping system. The steel support shall be designed, fabricated and
installed to withstand the full axial force (thrust) with minimal deflection.
AXIAL
DOUBLE O-RING EXPANSION JOINT
OR MECHANICAL EXPANSION JOINT
ANCHOR
SUPPORT
Product Series: 2000M & 7000M ( only applicable for up to 40” )
Size (mm)
50
80
100
125
150
200
250
300
350
400
450
500
550
600
650
700
750
800
900
1000
Axial Force(N)
at 5bar pressure
2168
4186
6550
9909
13230
24750
42934
55651
58450
73916
90372
110455
142671
156779
192423
222693
251296
288653
363534
443988
Axial Force(N) at
7.5bar hydrotest
pressure
3252
6280
9825
14864
19845
37125
64400
83477
87675
110874
135558
165682
214006
235168
288634
334040
376944
432980
545302
665982
Maximum
loading(N) of 3600
blank saddle
29480
45269
58188
72928
87889
115382
145249
173294
186488
213098
360487
396536
436518
476172
534994
576046
617181
658315
738034
822935
Remarks
4” length saddle blank
4” length saddle blank
4” length saddle blank
4” length saddle blank
4” length saddle blank
4” length saddle blank
4” length saddle blank
4” length saddle blank
4” length saddle blank
4” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
6” length saddle blank
Note: For other pressure ratings, the estimated axial force can be computed
linearly to the pressure. System hydro-test pressure (1.5 times of system
design pressure) shall be considered for support design.
Page 10 of 40
INS-MAR-01 (Rev9)
4.4 Support type and detail
The following support types are most common used for fiberglass piping system on
the shipboard and offshore projects.
4.4.1 Guide support
Guide supports permit longitudinal movement of the pipe but restrain lateral
movement. A guide support on horizontal pipe shall hold the pipe against
moving up and down. Guide supports shall be designed; fabricated and
installed that:
-
No direct contact between fiberglass pipe and steel support base/clamp
occurs. Protective material such as polyethylene, or PVC, or fiberglass
blank saddles shall be installed permanently;
-
A gap 0~5mm shall be maintained between pipe clamp and fiberglass
pipe.
-
Nut locking device (Extra nut, locking washer) is recommended.
STEEL
CLAMP
GAP 0-5 MM
LINING
CLAMP C/W LINING
SECTION VIEW - CLAMP
SLIDING SHOE
POLYETHYLENE/PVC
Note: Where the support is exposed to strong lateral force, the U-Bolt/Clamp type
guide support will NOT be recommended. In such circumstance, the two-half clamps
shall be installed.
CLAMP
0~3mm GAP
SPACER
IF REQUIRED
LINING
CLAMP
LINING
PIPE
Page 11 of 40
INS-MAR-01 (Rev9)
4.4.2 Fixed support (Light anchor)
Generally, fixed supports are installed on straight fiberglass pipe where both
ends are connected to mechanical expansion joint such as Mechanical
Expansion Coupling, Mechanical Flange Adaptor, Double O-Ring Expansion
Coupling, Double O-Ring Flange Adaptor, etc. The fixed support provides
restriction to both lateral movement and axial movement. Fiberglass saddles
are fixed onto fiberglass pipe as a stopper collar. The fixed support shall be
designed, fabricated and installed that:
-
No direct contact between fiberglass pipe and steel support clamp occurs.
Protective material such as rubber, or polyethylene, or PVC, or fiberglass
blank saddles shall be installed permanently;
-
Double nuts shall be installed for clamp bolts to prevent excessive
clamping force on pipe;
-
Axial gap between blank saddle and steel clamp shall not be greater than
3mm.
PIPE
CLAMP
CLAMP C/W LINING
0~3mm GAP
BLANK
SADDLE
4.4.3 Anchor support
Generally, anchor supports are installed to provide restrain to both lateral
movement and axial movement. Fiberglass saddles are fixed onto fiberglass
pipe as stopper collars. Strong force is expected on an anchor support. The
anchor support shall be designed, fabricated and installed in such a way that:
-
No direct contact between fiberglass pipe and steel support clamp,
protection material such as rubber, or polyethylene, or PVC, or fiberglass
blank saddles shall be installed permanently;
-
Double nuts shall be installed for clamp bolts to prevent excessive
clamping force on pipe;
-
Axial gap between blank saddle and steel clamp shall not be greater than
3mm;
Page 12 of 40
INS-MAR-01 (Rev9)
-
Support structure shall be strong enough to stand force caused by internal
pressure, separation force generated by free joint such as Double O-Ring
Joint and Mechanical Expansion Joint, calculated surge and so on.
CLAMP C/W LINING
0~3mm GAP
CLAMP
SUPPORT
BRACING
BLANK
SADDLE
4.4.4 Flange Frame
Flange frames are used for supporting flanged valves and flanged heavy inline
items independently. Flange frames can also be installed to pipe flange for
other supporting purpose. The flange frame can be fully welded to structure,
thus being a fixed type or anchor type support; also the flange frame can sit
loose on a support base with guide bars, thus being a guide type support.
The flange frame is connected to piping with bolts, and it might be exposed to
high axial force, thus it shall be designed, fabricated and installed that:
-
It must provide clearance with pipe body;
-
It is of the correct size and covers appropriate number of bolt holes;
-
The plate shall not be too high, thus to minimize bending stress on steel;
-
It is installed with reinforcement wedge plate if necessary;
-
It shall be bolted to flange prior to being fully secured to structure.
PIPE BODY
CLEARANCE
FLANGE
FRAME
WELDING
OR BOLTING
FLANGE FRAME
C/W WEDGE PL
SUPPORT
BRACING
Page 13 of 40
INS-MAR-01 (Rev9)
5
Receiving, Handling, Storage
5.1 Receiving
Inspect all shipments of fiberglass materials and accessories and do the following:
-
Verify packing list and material
-
Check material for any damage
Fiberglass pipe, fittings, fabricated spools, tools, accessories shall be inspected
immediately upon receiving and shipping agent is to be informed of any deficiency.
In the event of damage or missing items, relevant parties shall be informed
immediately.
5.2 Handling
The following recommendations are made to protect the fiberglass pipe, fittings and
fabricated spools against damage:
-
End protection shall remain in place during handling and transportation. End
protection can be removed for receiving inspection, but is shall be put back
immediately.
-
Fiberglass components shall be handled with care and protected from impact.
Throwing, dropping, bumping or hitting the fiberglass component is prohibited.
Fiberglass component shall not be dragged or pushed over sharp objects.
The use of a forklift truck is tolerated, provided that the forks are padded with carpeting
or some other suitable soft material.
5.3 Transportation
It is recommended to transport fiberglass materials in their original container and
original packing. In case the contents of the containers would be altered, attention
shall be paid to the following:
-
Do not let the fiberglass pipe and spools rest on the floor of the container where
nails, studs or other sharp objects might damage them;
-
The fiberglass pipe and spools shall be securely fastened directly over the
timbers with tie-downs such as nylon straps or ropes. Do not use steel wire ropes
or other sharp material, which might cause damage;
-
No other materials shall be loaded on top of the fiberglass components;
-
Do not drop the fiberglass products, walk or stand on them;
-
When stacking 12m lengths, a minimum of 4 wooden supports must be used to
separate each length;
-
Do not allow the fiberglass pipe to extend more than 2 meters beyond the truck
or trailer bed to prevent excessive bowing.
Page 14 of 40
INS-MAR-01 (Rev9)
5.4 Lifting
When the pipe and spool have to be lifted, the following has to be taken in to account:
-
When mechanical lifting is required, canvas or nylon slings are to be used. No
steel chains, wire ropes or clamps shall be used for lifting fiberglass pipe
components;
-
Pipe/spools up to 3m in length may be lifted with a crane using at least one
sling. Longer sections, up to 6m in length, may be lifted with a 3m spreader
bar and two slings. Twelve-meter long sections may be lifted with a 6m
spreader bar and two slings;
-
Cartons can be lifted by hand or, in case of pallet cartons, by using a forklift
truck. Do not throw or drop the cartons.
5.5 Storage
Storage of piping components may be required prior to installation. Special precautions
shall be taken to avoid damage.
5.5.1 Pipe
Fiberglass pipe may be safely stored outside for extended periods provided the
following recommended storage procedures be observed.
-
Supports shall be spaced at 3-meter intervals and approximately not more
than 1½ meter from each end. The supports should have a minimum 100mm
(4-inches) wide bearing surface. The supports (timbers) used in the NOVFGS containers can be used for this purpose at the storage area.
-
The pipe stack should not exceed 3m in height and should have side supports
or blocks to prevent rolling or slipping in the stack.
-
It is not recommended to stack pipes directly on the ground.
-
Protective end coverings must be left intact until the time of installation.
5.5.2 Fittings
Fittings shall be kept in cartons, stored on shelves, preferably inside a
warehouse.
5.5.3 Fabricated Spools
Pipe spools are packed by NOV FGS to avoid damage during transportation.
Spools shall be stored with temporary protection in place. If possible, spools
shall be stored in the original packing and shipping skid. When spools are
stacked after receiving inspection, sufficient wood spacers shall be placed in
between layers.
Page 15 of 40
INS-MAR-01 (Rev9)
5.5.4 Adhesives
Adhesives shall be stored indoors at temperatures between 5°C and 35°C.
Extended storage at higher temperatures will degrade the catalyst and the resin,
and reduce adhesive strength. Avoid storage of the adhesive in direct sunlight.
Adhesive shall be kept in original packing; it shall not be stored upside down.
Each adhesive kit is stamped with an expiration date. FIFO (First In, First Out) is
recommended for adhesive usage.
5.5.5 Accessories
Accessories such O-Rings, Nylon Keys, etc., shall be stored away from direct
sunlight and rain. The minimum storage temperature for O-Ring and Nylon Key
is 10°C.
5.5.6 Tools
Pipe shavers, arbors and power drive shall be kept in original toolbox after use.
These tools shall be kept in dry location.
Heating blankets shall be rolled up when not in used. Heating blankets shall
be kept in box or on a rack to avoid damage from any heavy objects. The
storage shall be away from direct sunlight and rain.
Page 16 of 40
INS-MAR-01 (Rev9)
6
Installation of Fiberglass Pipe
6.1 Adhesive bonding joint (Only applicable for up to 40” )
Site adhesive bonding joint shall be minimized so that to facilitate an efficient
installation. In the situation that adhesive bonding joint is inevitable, the adhesive
bonding joint shall be carried out by well-trained and qualified bonder in accordance
with NOV FGS adhesive bonding joint procedure.
INSERT
INSERT DEPTH
LENGTH
TAPER ANGLE
NOSE
THK
OD
QL JOINT
TAPER JOINT
6.1.1 Special Tools for adhesive bonding joint
Pipe shavers – to machined pipe end to required dimensions:
-
B1F for 1” ~ 6” Quick-Lock Male (QLM);
-
M74 for 2”~16” Quick-Lock Male (QLM) & Machined End (ME);
-
M86 for 2”~6” Taper Male (TM);
-
M87 for 6”~16” QLM, TM & ME;
-
M87XL for 16”~24” QLM, TM & ME;
-
M88 for 26”~40” QLM, TM & ME
Power Drive – is the power unit to drive M74, M86, M87, M87XL & M88
shavers;
Pipe Arbor – is required to fix shaver (M74, M86, M87, M87XL & M88) onto
pipe;
Heating Blanket – to heat cured adhesive bonding joint.
Note: Refer to relevant product literature for safety and proper use of tools.
6.1.2 Bonding Procedure
Brief adhesive bonding joint procedure is as follows:
-
Cut the pipe to required length;
-
Shave the pipe end to required dimensions (Diameter and length for
QLM; Nose thickness, Taper angle and length for TM)
-
Bonding surface preparation to ensure all bonding surfaces are clean,
non-glossy, fresh finish without oil and water contamination;
Page 17 of 40
INS-MAR-01 (Rev9)
-
Dry fit and mark alignment and reference;
-
Select and mix adhesive;
-
Apply adhesive to all bonding surfaces;
-
Assemble the joint and remove excessive adhesive;
-
Heat cure with heating blanket
-
Complete necessary documentation
Adhesive joints shall be bonded by qualified bonders only. For bonder
Qualification - please refers to Project Specification.
Note: Refer to relevant bonding procedure, or adhesive product literature for
detail guidance for adhesive bonding process and concerns, measures and
precautions for making quality bonding joint.
References:
PF-01-Assembly procedure of Quick lock joints-1-16inch, 18-40 inch
PF-02A Assembly procedure of Taper joints 8-40 inch-S2000M-7000M series
6.1.3 Lamination procedure for LD pipes ( 48” , 52” and 60” )
Brief bonding procedure is as below:
-surface preparation for lamination as per required laminated length
-prepare the materials and tools
-make sure the safe working place ( if staging is required, to be prepared )
-prepare the Putty, Hand lay up lamination resin and UV Top Coating resin as
per formulation
-Mix the resin with correct ratios
-Apply layers of Chopped Strand Mat (CSM) and Woven Roving (WR)
externally and internally.
-Ambient cure for one day
-must protect the curing of lamination joint from rain.
Reference :
LAM-52IN- Lamination procedure(B&W) with vinylester resin
Page 18 of 40
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Page 19 of 40
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6.2 Flange assembly
6.2.1 Gaskets
Use full-face gaskets of an elastomeric (Shore A Hardness 55~65) or other
compatible material, suitable for the service pressure, temperature and fluids
in the system. Gaskets shall be at least 3 mm thick.
6.2.2 Bolts
Well-lubricated new bolts shall be used. Lubricant should be chosen
according to project specification and COF (coefficient of friction) is
recommended to be 0.17. Bolt material and treatment shall be in accordance
with project technical specification. Plain washers shall be installed on all
fiberglass flanges to prevent damage. Spring washer shall not have direct
contact with fiberglass flange.
In general, stud bolts shall be used. Bolts shall be placed only when they are
ready to tighten the flange joint. In the situation where it is difficult to place
bolt after spool/flange placement, the bolts shall be preset in the flange.
6.2.3 Assembly
Mount lubricated washers under both nuts and bolt heads to avoid damage of
the flange back-face. Tighten all nuts following the sequences given in
"Tightening sequence".
Do not exceed the maximum torque given in "Recommended Bolt Torques".
After all bolts have been tightened to the recommended torque, recheck the
torque on each bolt in the same sequence, since previously tightened bolts
may have relaxed.
Excess torque and uneven tightening can damage the flange.
6.2.4 Flange mounting misalignment tolerances
The alignment of the flanges is very important. Force the bolts to align a
mismatch flange pair will result in damage on fiberglass components and/or
leaking at bonding joint. When a flange joint is assembled, the maximum
misalignment shall not exceed the recommendation shown below. Otherwise,
the pipe work must be rectified to correct the alignment.
Size
Maximum Misalignment Allowance
A
B
Up to 16”
1/16”
1.6 mm
1/8”
3.2 mm
18” – 40”
3/32”
2.4 mm
3/16”
4.8 mm
42”-60”
3/32”
2.4 mm
3/16”
4.8 mm
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INS-MAR-01 (Rev9)
Flange pair offset results in difficulty of bolt installation. The maximum
offsets are given in table below.
OFFSET
6.2.5 Recommended Bolt
Torque
Size
Maximum Offset Allowance (mm)
JIS5K
JIS10K DIN10 CL150
2” to 22”
3.0
3.0
2.0
3.0
24” – 40”
3.0
3.0
3.0
3.0
42”-60”
4.0
4.0
4.0
4.0
To achieve full pressure seal, bolt tightening should achieve a torque from
80% to 100% of “Torque Full Pressure Seal” as the recommended torque. To
prevent damage, the bolt torque shall not be more than “Maximum Torque”
shown in the table.
Hub Flanges:
Flange
Size
2 - 4 Inch
6 - 12 Inch
14 - 16 Inch
Initial
Torque
10 Nm
20 Nm
30 Nm
Torque
Full Pressure Seal
30 Nm
40 Nm
70 Nm
Maximum
Torque
40 Nm
50 Nm
85 Nm
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INS-MAR-01 (Rev9)
Heavy Duty Flanges:
Flange
Size
1 - 1,5 Inch
2 - 4 Inch
6 - 8 Inch
10 - 14 Inch
16 Inch
18 - 20 Inch
22 - 40 Inch
42 – 60 Inch
Initial
Torque
10 Nm
20 Nm
30 Nm
50 Nm
100 Nm
200 Nm
250 Nm
250 Nm
Torque
Full Pressure Seal
30 Nm
60 Nm
80 Nm
150 Nm
250 Nm
400 Nm
500 Nm
550 Nm
Maximum
Torque
40 Nm
75 Nm
100 Nm
180 Nm
300 Nm
480 Nm
600 Nm
660 Nm
Initial
Torque
20 Nm
50 Nm
100 Nm
200 Nm
300 Nm
Torque
Full Pressure Seal
60 Nm
100 Nm
200 Nm
400 Nm
600 Nm
Maximum
Torque
75 Nm
120 Nm
250 Nm
480 Nm
750 Nm
Stub end Flanges:
Flange
Size
1 - 4 Inch
6 - 12 Inch
14 - 16 Inch
18 - 24 Inch
26 - 40 Inch
6.2.6 Tightening Sequence as per ASTM D4024
Remark: tightening sequence for other no. of holes to be followed as same bolting
method mentioned above.
Page 22 of 40
INS-MAR-01 (Rev9)
6.3 Double O-Ring Joint Assembly (Only applicable for up to 40”)
6.3.1 Preparation and pre-set
Inspect all connecting surfaces of fiberglass Double O-Ring to ensure there
are no scratches and damage on Double O-ring Male (DOM) end, Double Oring Male Key (DOMK) end, and inner surface of Double O-ring Female
(DOF). Clean all connecting surfaces so that there are free of oil, dirt, loose
scale, and so on.
Hull Block Joint
The Double O-ring Expansion Coupling shall be preset onto DOMK end. The
preset work shall be done during block installation stage and/or prior to
placement of connection spools.
DOMK End Double O-Ring
Expansion Coupling
KEY GROOVE
KEY HOLE
The Double O-ring Expansion Coupling shall be preset in right direction, i.e.
the key-hole side of the Double O-ring Expansion Coupling shall be at the far
side of the joint.
The Double O-ring Expansion Coupling shall be secured onto pipe, and it
shall be wrapped together with DOM end to prevent burning damage and
impact damage, and also to protect against contaminated of dirt and debris.
6.3.2 Insertion depth and Accessories
Refer to below table for standard insertion depth, O-ring size and Nylon-Key
size.
O-RINGS
NYLON KEY
O
OS
Page 23 of 40
INS-MAR-01 (Rev9)
Size
(mm/Inch)
50
80
100
125
150
200
250
300
350
400
450
500
550
600
650
700
750
800
900
1000
2”
3”
4”
5”
6”
8”
10”
12”
14”
16”
18”
20”
22”
24”
26”
28”
30”
32”
36”
40”
DOM
Insertion
(Os) mm
81
81
81
102
105
138
148
175
185
195
178
186
210
210
247
250
257
292
347
340
DOMK
Insertion
(O) mm
91
91
91
112
115
149
158
185
195
205
188
197
220
220
257
260
267
302
357
350
O-Ring
Nylon Key
7 x 59.7
7 x 88.3
7 x 113.7
9 x 135
10 x 161.3
10 x 225
12.5 x 302
12.5 x 342.3
12.5 x 342.3
12.5 x 393.1
15 x 445
15 x 490
18 x 556
18 x 580
18 x 622.3
20 x 685
20 x 740
20 x 790
25 x 890
26 x 987
6 x 305
6 x 400
6 x 483
8 x 580
8 x 660
10 x 840
12 x 1270
15 x 1270
15 x 1360
18 x 1585
15 x 1750
15 x 1930
18 x 2100
18 x 2240
18 x 2510
20 x 2700
20 x 2700
20 x 3065
25 x 3175
20 x 3500
6.3.3 Inspection prior to assembly
To ease installation, to obtain proper assembly, and to avoid unnecessary
stress to Double O-ring Joint and its component, following dimensional
criteria shall be inspected prior to final assembly:
Page 24 of 40
INS-MAR-01 (Rev9)
BEFORE INSTALLATION
50 ±10 (FOR 2"-6")
50 ±20 (FOR 8"-40")
E
− Gap between connecting pipes (For Double O-ring Coupling joint), the
gap shall be 50mm for standard design, the tolerance is ±10mm for
pipe size 6”(DN150) and below, and ±20mm for pipe size 8”(DN200)
and above;
− Offset between connecting pipes shall be within allowable tolerance
specified in table below;
DOR Joint – Allowable Offset
Pipe Size Range (mm)
Offset (mm)
2”-5” (DN50-125)
3.0
6”-8” (DN150-200)
4.0
10”-12” (DN250-300)
5.0
14”-16” (DN350-400)
5.0
18”-20” (DN450-500)
5.0
22”-40” (DN550-1000)
5.0
− All connecting surfaces are in good condition without scratches and/or
structural damage;
6.3.4 Assembly integral DOF – DOM Joint
When ready to join the pipe, remove the dirt and debris from o-ring grooves
using compressed air, a clean rag or a paintbrush;
Brush or rub a layer of vynoleo grease into o-ring grooves, pipe end, and male
end surface, and all inside surfaces of the female end. (Apply lubricant only
when you are ready to assemble the joint) Keep lubricated surfaces clean and
free of sand and dirt.
Lubricate entire surface of o-ring and slip them into both grooves on the male
end, distribute each o-ring evenly in the groove by slipping a screwdriver
under them and sliding the screwdriver around the joint;
Page 25 of 40
INS-MAR-01 (Rev9)
Mount band clamps (with D-rings) a convenient distance on each side of the
joint, hook up band clamps with come-a-longs or lever hoists;
Tighten the come-a-longs or lever hoists to pull mating pipe to join together
until the center scribe line is aligned with the leading edge of the female end.
AFTER INSTALLATION
LEADING EDGE
C
A
A
MIN. INSERT
TARGET
MAX. INSERT
6.3.5 Assembly Double o-ring expansion coupling
When ready to join the pipe, remove the dirt and debris from o-ring grooves
and inner surface of Double o-ring expansion coupling using compressed air,
a clean rag or a paintbrush;
Brush or rub a layer of vynoleo grease into o-ring grooves, key groove, pipe
end, and male ends surface, and inner surface of the Double o-ring expansion
coupling. (Apply lubricant only when you are ready to assemble the joint)
Keep lubricated surfaces clean and free of sand and dirt.
Lubricate entire surface of o-ring and slip them into grooves on the male ends.
Distribute each o-ring evenly in the groove by slipping a screwdriver under
them and sliding the screwdriver around the joint;
Using band-clamps (with D-rings) and come-a-longs/lever hoists to pull
Double O-ring Expansion Coupling to the DOM end till the leading edge of
Double O-ring Expansion Coupling is aligned with scribe line on the DOMK
end;
Lubricate the nylon-key and insert it into keyhole till the leading end of nylonkey can be seen from keyhole. (Note: Over insertion will result in difficulty of
key extraction);
After installation, inspect the insertion depth; the edge of Double O-Ring
Expansion Coupling shall fall in between maximum and minimum insertion
scribe lines. Check angular deflection to ensure alignment is within tolerance.
Page 26 of 40
INS-MAR-01 (Rev9)
ANGULAR DEFLECTION
DOR Joint – Allowable Angular Deflection
Pipe Size Range (mm)
α
2”-16” (DN50-400)
0.5º
18”- 28” (DN450-700)
0.7º
30”-36” (DN750-900)
0.5º
40” (DN1000)
0.7º
6.3.6 All o-rings and nylon keys for the GRE expansion couplings are to be kept in a
cool dry place, away from heat or direct sunlight to prevent deterioration of the
materials.
6.4 Mechanical Coupling Joint Assembly ( Only applicable for up to 40” )
Mechanical coupling can be used to join fibreglass pipe to fibreglass pipe, and also
fibreglass pipe to metallic pipe. For mechanical expansion coupling installation and
joint assembly, and its requirement on pipe outside diameter, insertion length,
alignment tolerance and so on, refer to specification and recommendation from
product manufacturer.
6.4.1 Preparation and pre-set
Inspect machined fiberglass pipe ends to ensure there are no scratches or
damage. Clean pipe-ends so that pipe ends are free of oil, dirt, loose scale and
rust.
Page 27 of 40
INS-MAR-01 (Rev9)
Mechanical
Expansion Joint
Machined
Pipe End
Hull Block Joint
The preset work shall be carried out during block installation stage, and/or
prior to placement of connection spools.
Detail steps are as follows:
− Slip one follower ring over pipe end;
− Wipe one gasket clean and immerse in soapy water (Glycerine may be
added in freezing weather) and slide the rubber gasket over the pipe
end;
− Loosen (Screw out) the stop bolt of middle ring;
− Clean coupling middle ring, paying attention to flares on ends where
gaskets will seat, then slip the middle ring over one pipe-end;
− Wipe the other gasket clean and immerse in soapy water, and slide it
over the pipe end;
− Slip the other follower ring over pipe end;
− If final joint assembly is not carried out immediately, slide gaskets and
followers together with middle ring; insert bolts and temporary
assemble the expansion coupling.
6.4.2 Inspection
When connecting pipes are placed, the following shall be inspected prior to
final joint assembly:
− Gap between connecting pipes, the gap shall be 70±30mm for “Long”
type expansion joint;
− Angular deflection and offset between connecting pipes shall be within
allowable tolerance specified by manufacturer;
Page 28 of 40
INS-MAR-01 (Rev9)
− Connecting pipe ends are in good condition without scratches and/or
structural damage;
6.4.3 Assembly
Dismantle all bolts of preset mechanical coupling;
Clean pipe-ends so that pipe ends are free of oil, dirt, loose scale and rust;
Slip one follower ring over the other pipe end;
Wipe one gasket clean and immerse in soapy water again if necessary, and
slide the rubber gasket over the other pipe end;
Slip the middle ring over the joint and center it;
Slip rubber gaskets and followers into place, making sure gaskets are pushed
under middle ring flare all the way round;
Insert bolts and tighten bolts to uniform bolt torque specified by manufacturer.
Tightening sequence shall follow flange-tightening sequence.
Screw in the stop bolt of middle ring.
6.5 Connection to Other Materials
Where possible, connect fiberglass piping to either metallic or thermoplastic piping
using flanges. Fiberglass flanges may be bolted directly against raised-face steel
flanges. Fiberglass flanges also seal well against lined steel configurations.
Flanged valves and other equipment are frequently supplied with different flange
facings. The configuration of these facings may vary widely. Unless it has been
Page 29 of 40
INS-MAR-01 (Rev9)
demonstrated that these facings are compatible with the face of fiberglass flanges,
consult NOV FGS Engineering.
Where fiberglass piping is connected to metallic pipe, securely anchor the metallic
pipe at the point of connection so that expansion and contraction or weight of the
metal line is not transferred to the fiberglass line.
All welding work on metallic piping that is
adjacent to fiberglass piping shall be completed
prior to joining to fiberglass piping; otherwise,
cooling devices shall be in place to prevent heat
transfer.
When instrumentation and metallic piping is
threaded on fiberglass component, the fiberglass
component must be properly held with spanner to
prevent damage caused by torque force.
6.6 Connections to equipment, tanks, pressure vessels
Bondstrand pipe will safely absorb vibration from pumping or other conditions if
stresses are controlled within reasonable limits. In general, pipeline vibration is
severe only when the generating frequency is at, or near, the natural resonance
frequency of the pipeline. This frequency is a function of the support system, layout
geometry, temperature, mass, and pipe stiffness, and is often difficult to predict.
To control stress caused by vibration. It is usually to observe the stability of the
system during initial operation and add restraints or supports as required to reduce
effects of equipment vibration. In special cases where source vibration is excessive,
an elastomeric expansion joint or other vibration absorber should be considered.
The wall flexure of a tank/pressure vessel as it is filled and emptied produces
movements at nozzles that must be accommodated in the design. These movements
can be absorbed by a loop or turn, or by an expansion joint. Avoid direct, straight-line
connections between tanks.
6.7 Maximum allowable misalignment tolerances
Force to joint misaligned fiberglass piping will result in damage on fiberglass
components and/or leaking at bonding joint. When fiberglass piping is jointed, the
misalignment shall not exceed maximum allowable misalignment tolerances shown
below.
Page 30 of 40
INS-MAR-01 (Rev9)
Pipe Size Range
Maximum Tolerance – h6m (C=6m)
mm
Up to 4”
25
6” – 12”
19
14” – 20”
12.5
24” – 40”
10
42”-60”
6.5
Maximum Tolerance for support spacing “C” can be computed in following formula:
h = h6m x C2 / 36
Where:
“h” – Maximum Allowable Misalignment;
“C” – Support Span in Meter
“h6m” – Maximum Allowable Misalignment at support span of 6m.
6.8 Installation in Hull/Topside Block
Fiberglass fabricated spools shall be placed into hull/topside blocks in block stage.
The fiberglass spools shall be installed into hull/topside blocks after block painting
and blasting. If fiberglass spools have to be installed into hull/topside blocks prior to
blasting and painting, the fiberglass spools shall be wrapped with protection canvas or
equivalent protection materials.
When the fiberglass piping is exposed to the possibility of damage by falling objects,
the fiberglass piping shall be protected by wooden planks on top. The protection
wooden plank shall be secured.
During installation in hull/topside block, fiberglass pipe/spool shall be handled with
care, surrounding hazards shall be observed all the time, thus to prevent:
Page 31 of 40
INS-MAR-01 (Rev9)
− Impact damage due to dropping to hull/topside structure or collision with
hull/topside structure;
− Scratch damage when pipe/spool passing through a manhole and/or opening on
non-watertight bulkhead.
During block installation stage, it is recommended to:
− Not fully weld the bulkhead penetration piece so that adjustment at steel can be
done at later stage to accommodate minor piping misalignment;
− Not fully weld the support structure so that piping alignment can be easily
adjusted after block joint;
− Install Mechanical Expansion Coupling on the pipe end in accordance with
predetermined location shown on layout, or,
Install Double O-Ring Expansion Coupling at pipe end with Key-Groove,
Machined
Pipe End
Hull Block Joint
Mechanical
Expansion Joint
Hull Block Joint
The Mechanical Expansion Coupling or Double O-Ring Expansion Coupling
shall be secured on the pipe during block transportation;
DOMK End Double O-Ring
Expansion Coupling
− All pipe/spools installed shall be secured during block transportation.
Page 32 of 40
INS-MAR-01 (Rev9)
7
Test of Fiberglass Pipe System
7.1 Hydro-test
‘The hydrotest is considered to provide the best assurance of a GRP pipe system’s
integrity’ (ISO14692:4, Annex-E). Installed fiberglass piping shall be hydrotested to
ensure successful installation. Refer to AME/INS-004, ‘Hydro-Testing Procedure for
Bondstrand GRE/GRV Pipe’ for comprehensive recommendations and guides.
7.1.1 Test general recommendations
Every part that has to be tested shall be vented until free of air. Be aware that
there is always a possibility of the presence of entrapped air in a system.
Before testing, all lines or systems shall be inspected to ensure that all
connected parts to be excluded from the test are removed and/or isolated.
The piping system must be completed with support installation.
During pressure testing the fiberglass pipe system shall be continuously
monitored in order to prevent damages, especially at branches and elbows,
due to snaking and expansion of the fiberglass pipe.
Pressure gauges and instrument must be calibrated and within 6 months
period. Appropriate pressure gauge shall be used, the test pressure shall be
between 30% to 75% of the reading range. If possible, pressure recorder shall
be used.
7.1.2 Test medium and test pressure
The system shall be hydrostatically tested with fresh industrial water; water
used for testing shall be clean and free from filth or un-dissolved solids of any
description.
The test pressure shall be 1.5 times of the system design pressure, the test
pressure shall be held for one hour minimum or sufficient time to carry out
line check, whichever is longer.
The test pressure shall be brought up slowly and gradually to allow for
equalizing for strain during the test, and in stages to allow checking for leaks
and inspection of the system. In doing so, no fast closing valves and booster
pumps shall be used. In any case, the test pressure shall be raised over a
period of 30 minutes or longer.
7.1.3 Inspection, acceptance criteria, and approval
Inspection shall be carried out by means of instrument reading and visual line
check to ensure the system is:
− No sign of leaking or weeping;
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INS-MAR-01 (Rev9)
− No sign of significant pressure lost. The pressure lost during hydrotesting must be accountable;
− No deflection / damage due to hydro-test pressure on any support
structure.
The Hydro-test report shall be endorsed by all relevant parties after successful
completion of hydro-test.
7.1.4 Effect of temperature
The test pressure gauge/recorder has to be kept under observation so that any
change in pressure can be controlled and compensated immediately. An
increase of pressure could cause damage to the fiberglass system.
It should be noted that variation of water-temperature in the system, could
affect the pressure significantly.
When ambient temperature falls below 0°C, glycol antifreeze shall be added
into test medium.
7.1.5 Reinstatement
After system hydro testing, all items that were removed before hydro testing
shall be reinstated.
7.1.6 Safety
As in any system where pressure is employed, adequate safety precautions
shall be exercised. The following safety precautions are recommended as
minimum, but not limited to:
− The piping system is free from air;
− Safety devices are installed in test system;
− Qualified and experienced personnel shall operate pressurizing equipment.
Untrained and unauthorized personnel shall not be near the test equipment
and test area.
− Necessary signs, notice boards and barricade shall be in place.
7.2 Conductivity test (For Conductive System Only)
For installed piping, conductivity test shall be carried out to verify the conductivity
between fiberglass piping and earth points.
Ohmmeter (0~20 M-Ohm) shall be used for conductivity test. The end of probe of
Ohmmeter shall be wrapped with wet sponge. This increases the “footprint” of the
probe and gives better indication of suitability.
7.2.1 Test methods
When conductivity of installed piping is checked, apply one probe with wetted
sponge to the pipe surface as indicated on sketch below. The pipe surface
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INS-MAR-01 (Rev9)
must be sanded to expose the carbon fiber prior to checking. The sanded
surface shall be painted after testing.
To avoid additional work on sanding and painting pipe surface, alternatively,
back of fiberglass flange and adhesive bonding fillet between pipe and fitting
could be used as testing point.
Apply the other probe directly onto metallic structure that is near to earth
point, and record the reading.
7.2.2 Acceptance criteria
For installed piping, the resistance reading must not exceed 1.0 Mega Ohm
between two sides of site bonding joints, and also between piping and earth
point.
Page 35 of 40
INS-MAR-01 (Rev9)
8
Field Modification and Repair
Recommendations here are based on the philosophy that the modification/repair should
be permanent. It is therefore recommended that all damaged, impacted or sheared areas
be cut out and replaced with new pipe/fitting.
8.1 Modification and repair procedure
When field modification is required, or when damage, impact and leaking are
observed and necessary site repair is required, it is recommended to carry out
following processes:
-
Site inspection, collecting necessary information/document (such as drawings,
reports, safety requirement, etc);
-
If applicable, study the cause of defect/failure and work out corrective action
plan to prevent re-occurrence;
-
Prepare modification/repair proposal and submit to relevant parties for approval,
the proposal shall contain, but not limited to:
Modification/Repair method;
Work description;
Material requirement;
Tools/Equipment requirement;
-
Carry out modification/repair work in accordance with relevant procedures;
-
Report and/or Record modification/repair work.
8.2 Modification and repair general concerns
The modification/Repair work shall be carried out by qualified fiberglass pipe
bonder/fitter;
The modification/repair piping must be depressurized and emptied prior to
modification/repair work;
It is recommended to preheat existing pipe if the piping has been filled with water;
After modification or repair, the piping section containing the modification and repair
shall be re-certified by performing a pressure test.
8.3 Common modification and repair methods
8.3.1 Partial replacement
Partial replacement is to replace pipe and fitting (Including flange) which has
problem on the body and/or at the bonding joint. The new pipe and fitting
shall be jointed with existing piping in accordance with appropriate jointing
procedure. It is recommended to assemble the existing pipe and new pipe with
coupling. Alternatively, “Lamination (Butt & Wrap)” is commonly used
jointing method for pipe-to-pipe joint.
Page 36 of 40
INS-MAR-01 (Rev9)
Adhesive
Bonding
Coupling
Alternative: Lamination
(Butt & Wrap) Joint
When partial replacement is applicable:
-
Careful inspection should be made to ensure that all imperfections/leaks
etc. are identified;
-
Cut out damaged section with consideration of extension of the damage,
sufficient left-over pipe length for shaving or lamination, sufficient length
to accommodate new pipe and fitting;
-
Assemble new pipe, and/or new fitting, and/or new spool with existing
piping in accordance with appropriate joint assembly procedures.
8.3.2 Over-wrap
Over-wrap can be applied to minor damage pipe and fitting, and minor
leaking adhesive bonding joint. The Over-wrap is good to use in places where
it is not practical to partial renew due to space constraint, insufficient time
schedule, lack of replacement pipe/fittings, and so on.
When Over-wrap is applicable:
-
The sharp corner of bell of pipe or bell of fitting shall be chamfered to
obtain a smooth transition area;
-
All loose fiber must be removed, and the damage part must be coated with
adhesive or resin prior to lamination;
Page 37 of 40
INS-MAR-01 (Rev9)
-
Following over-wrapping procedure for surface preparation, building
structural laminates, curing, and post work finishing, and so on.
-
Lamination length and number of layers depends on system design
pressure.
8.3.3 Surface repair
The method can be used minor defects that pipe/fitting structure is not
damaged and there is no sign of leaking, such as minor scratch; surface crack;
adhesive fillet crack; minor surface burning; and so on.
The repair work shall be carried out in following sequence:
-
Lightly sand down the affected area (Such as minor scratch, surface
crack);
-
Apply a thin coat of adhesive, or spray paint, the adhesive and paint shall
be compatible with product material;
-
Leave the coating for self-curing at ambient temperature.
8.4 Temporary repair
A temporary repair should only be utilized when it is unfeasible to shut down the pipe
system to install a permanent repair. Temporary repair may be carried out as agreed
by owner, repair kit manufacturer and NOV-FGS.
A range of techniques are available which include, but are not limited to, overwrap
with water activated resin-glass tape, self-sealing clamps.
It must be recognized that NOV FGS does not endorse the long-term performance of
the temporary repair, and it is recommended to install a permanent repair as soon as
circumstances permit.
8.5 Other methods and solutions
When above methods are not appropriate for the defect and failure, when it is
difficulty and limitation to adopt above methods, consult NOV-FGS engineering for
other modification/repair method and case-to-case solution.
Page 38 of 40
INS-MAR-01 (Rev9)
9
Safety Recommendation
Always refer to the Material Safety Data Sheet (MSDS) prior to working with unfamiliar
materials or if there are questions concerning the contents of the fiberglass product and
materials.
9.1 Dust Hazards
When machining fiberglass pipe, worker may be exposed to dust. This dust is
considered as non-hazardous, however, in high concentrations it may cause a
temporary irritation of the skin. This exposure can be minimized by following the
guidelines. Keep the dust concentration below the MAC value (10 mg/m3).
-
Keep working area properly ventilated to maintain low dust concentration;
-
Wear long-sleeved shirts along with long trousers;
-
Wear safety glasses, goggles or a face shield to protect eyes from dust. A
disposable dust mask shall be used when grinding or sanding the material;
-
Shower in cool water with mild soap to reduce irritation;
-
Do not rub or scratch irritated skin;
-
Wash work clothes separately;
-
Follow below mentioned procedures if irritation caused by contact with glass
fibers:
o Skin-wash with cool water.
o Eyes-flush with running water for at least 15 minutes and seek medical
attention if irritation does not stop at the completion of the flushing.
9.2 Chemical Hazards
The adhesive is compound of resin and hardener. The hardener is irritating to skin,
eyes and respiratory tract. It is toxic orally and may cause sensitization. The resin
may be mildly irritating to skin, eyes and respiratory tract. Avoid contact with eyes,
skin or clothing, and avoid breathing vapor.
Disposable polyethylene gloves or equivalent shall be used to avoid contact of
adhesive with the skin. Wear safety glass to avoid contact of adhesive with eyes.
In case of contact:
-
Eyes: Immediately flush eyes with plenty of water for at least 15 minutes, then
call a physician;
-
Skin: Wash skin with soap and water;
-
Clothing: Remove contaminated clothing and wash before reuse;
-
Inhalation: Remove to fresh air. Give oxygen or artificial respiration if
necessary.
Page 39 of 40
INS-MAR-01 (Rev9)
9.3 Spill and Disposal
When handling resin and/or adhesive, the surrounding area shall be covered with
paper carton to avoid spill.
For small spill, apply sand or other absorbent material onto the resin and shovel the
mixture into a container. Large spill should be contained with a dike and the excess
resin shall be collected in container. Any residue resin should be removed from the
floor with hot, soapy water.
Caution: The use of solvents in the final cleanup can pose unnecessary hazards from
breathing vapors and possible ignition.
Disposal practice shall be in compliance with local laws and regulations, and other
regulations applicable. The preferred waste management option for unused,
uncontaminated, unformulated, unaltered resins is to send them to a licensed or
permitted recycler, reclaimer, or incinerator. The same waste management options are
recommended for used or contaminated materials.
Important Notice
This literature and the information in it are based on data believed to be reliable.
However factors as environment, application or installation, changes in operation
procedures, or extrapolation of data may cause different results. NOV FGS makes no
warranty, express or implied, including warranties of merchant ability or fitness for
purpose, as to the accuracy, adequacy or completeness of the recommendations and
information contained herein. NOV FGS assumes no liability whatsoever in connection
with this literature or the information or recommendations it contains.
Copyright
All Rights Reserved. This document contains information proprietary to NOV FGS
Singapore (Pte) Ltd. Any disclosure, or use is expressly prohibited, except upon explicit
written permission by NOV FGS Singapore (Pte) Ltd.
Revision Notes
13th Apr 2007
General revision and correction for language clarity.
16th May 2008
Added caution statement on exposure of o-rings to sunlight (6.3.6)
12th Aug. 2009
Added in Double O-ring adaptor joint support span sketch (4.2.2)
20th May 2010
Modified torque date for Heavy Duty type flange (6.2.5)
7th Oct. 2011
Revise table in page 10 of 37.
27th Feb.2012
27th Aug 2015
11th Aug 2016
Revise Bonding Procedure (6.1.2) and change NOV logo
Revise on General procedures of LD pipes ( 48”-60” )
Revise on #4.3 Axial load on anchor support
Page 40 of 40